Lifetime Prediction Abstract

EUROPEAN POWER SUPPLIES MANUFACTURERS’ ASSOCIATION
(Visit the EPSMA website at www.epsma.org)
Guidelines for Lifetime Specification

of Power Converters
Document Revision: First Edition, October 2020
ABSTRACT
Full document available to EPSMA members
Paper prepared by the EPSMA Technical Committee. Special thanks and acknowledgements to the
report champion Hubert Schoenenberger (PULS GmbH), Esa Väkeväinen (Murrelektronik Power), Dave
Collins (Artesyn), Francesco Di Domenico (Infineon), Martin Neudecker (TDK) and Andreas Braun
(Nippon Chemi-Con) for their contribution to this document.
The European Power Supplies Manufacturers’ Association was established in 1995, to represent the
European power supply industry.
Disclaimer: No responsibility or liability can be accepted by the EPSMA or any of its officers or members for the content of this
guidance document and the information contained herein should not be used as a substitute for taking appropriate advice.
Published by EPSMA © 2020

EPSMA 2
Lifetime Specification of Power Converters - ABSTRACT
Index
1 Aim / Objectives ...................................................................................................................... 4

2 Terminology............................................................................................................................. 4
2.1 Examples of Lifetime/MTBF confusion................................................................................ 4
2.2 Differentiating Lifetime from MTBF .................................................................................... 4
2.3 Example of Components with short lifetime but long MTBF .............................................. 4
3 Factors affecting product lifetime ........................................................................................... 5
3.1 Unit Life Expectancy ............................................................................................................ 5
3.2 Electrical Stress .................................................................................................................... 5
3.3 Mechanical Stress ................................................................................................................ 5
3.4 Climatic Stress ..................................................................................................................... 5
3.4.1 Temperature................................................................................................................ 5
3.4.2 Altitude, Air pressure .................................................................................................. 5
3.4.3 Humidity ...................................................................................................................... 5
4 Lifetime prediction of key components .................................................................................. 6
4.1 Aluminium Electrolytic Capacitors ...................................................................................... 6
4.1.1 Failure Mechanism ........................................................ Error! Bookmark not defined.
4.1.2 Stressors ........................................................................ Error! Bookmark not defined.
4.1.3 Lifetime Estimation........................................................ Error! Bookmark not defined.
4.2 Film Capacitors .................................................................................................................... 6
4.3 Analog Optocouplers ........................................................................................................... 6
4.4 Fans...................................................................................................................................... 6
4.4.3 Fan lifetime Estimation.................................................. Error! Bookmark not defined.
4.5 Semiconductors ................................................................................................................... 6
4.6 Rechargeable Batteries ....................................................................................................... 6
4.7 Thin Film Resistors............................................................................................................... 6
4.8 Electromechanical Parts (Contact Components)................................................................. 6
EPSMA 3

4.9 Inductive Parts ..................................................................................................................... 6
4.10 Metal Oxide Varistor (MOV) ............................................................................................ 6
5 Conclusions: Optimized Datasheet Specification for Lifetime ................................................ 6
6 References ............................................................................................................................... 7
EPSMA 4
1 Aim / Objectives
Customers and even suppliers of power products sometimes confuse lifetime with Mean Time
Between Failure (MTBF), as both are expressed in hours. This document distinguishes between these
two specifications with an emphasis on lifetime and might be regarded as an amendment to EPSMA
publication “Guidelines to Understanding Reliability Prediction“ from 2005 [1] explaining
reliability/MTBF.
Lifetime terminology and formulae are shown in relation to MTBF and the stresses that affect the
lifetime of components are discussed.
Components that contribute the most significant limitation to lifetime are examined to show what
factors affect their lifetime.
The paper concludes with a summary of key points to be considered when including lifetime data
in a data sheet, to help the end-user calculate the expected service life of their end product.
2 Terminology
2.1 Examples of Lifetime/MTBF confusion

When talking about reliability there has been confusion in understanding the difference between
mean time between failures (MTBF) and lifetime figures in a datasheet. A power converter might be
rated with an MTBF of >1,000,000 hours, but only with a lifetime expectancy of 30,000 hours. One
might wonder, why there is such a large difference?
2.2 Differentiating Lifetime from MTBF

In this chapter, definitions of Failures In Time (FITs), ‘failure rate ’, ‘lifetime’, ‘reliability
function R(t)’ and ‘failure distribution function F(t)’ are given. The so-called ‘bath-tub’ curve is
explained with its description of infant mortalities, operational failure rate and wear-out.
Mathematical relationships between the different quantities are given.
λ0
Figure 2.1 Failure Rate Bathtub Curve (© PULS LP)
2.3 Example of Components with short lifetime but long MTBF

In this section, an example is given of an application demanding very high reliability, measured in
millions of hours MTBF, but short lifetime, measured in minutes.
EPSMA 5
3 Factors affecting product lifetime
3.1 Unit Life Expectancy

This section discusses how lifetime is affected by the weakest part in a system and what a
reasonable definition of ‘end of life’ might be. It is pointed out that environmental stress is a major
factor in determining lifetime but there are also effects, specific to power supplies, such as on/off
cycling, which are also factors.
3.2 Electrical Stress

This section discusses the particular electrical stresses that apply to power supplies because of
their position in systems as an interface between AC source and load under different environmental,
load and nominal supply conditions. The potential effects of stress on functionality, lifetime and safety
are discussed.
3.3 Mechanical Stress

In this section, types of mechanical stress and their effects are discussed. Mention is made of HALT
(Highly Accelerated Life tests) for identification of weakest parts.
3.4 Climatic Stress
3.4.1 Temperature
The effect of temperature on lifetime of power supply products is discussed in this section with
reference to the ‘Arrhenius’ equation to identify acceleration factor. Failures induced at high and low
temperatures are mentioned.
3.4.2 Altitude, Air pressure

This section outlines the effect of altitude and corresponding low air pressure on cooling efficiency
and consequent lifetime degradation of power supply products.
3.4.3 Humidity
The effect of humidity on lifetime of components is discussed in this section with reference to ‘Peck’s’
equation.
EPSMA 6
4 Lifetime prediction of key components

In the full document, the following sections describe the failure mechanisms, stressors and
analytical method for evaluating lifetime of a range of components typically used in power supply
products. Methodology used by different component suppliers is described, with standards
referenced as relevant. In the full document, references are made to web tools for analysis and there
is also an embedded excel tool for lifetime prediction of aluminium electrolytic capacitors.
4.1 Aluminium Electrolytic Capacitors
4.2 Film Capacitors
4.3 Analog Optocouplers
4.4 Fans
4.5 Semiconductors
4.6 Rechargeable Batteries
4.7 Thin Film Resistors
4.8 Electromechanical Parts (Contact Components)
4.9 Inductive Parts
4.10 Metal Oxide Varistor (MOV)
5 Conclusions: Optimized Datasheet Specification for Lifetime

This paper shows how the lifetime of components is affected by stresses from the operating
environment and the way the product is used. In this section, the paper is summarised and further
guidance is given on analysis methods.
EPSMA 7
6 References
1. References to other EPSMA documents, publications and supplier data relevant to life time
prediction.

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EUROPEAN POWER SUPPLIES MANUFACTURERS’ ASSOCIATION

(Visit the EPSMA website at www.epsma.org)

Guidelines for Lifetime Specification

Document Revision: First Edition, October 2020

Published by EPSMA © 2020

1 Aim / Objectives ...................................................................................................................... 4

4.8.2 Stressors ........................................................................ Error! Bookmark not defined.

2.1 Examples of Lifetime/MTBF confusion

2.2 Differentiating Lifetime from MTBF

Figure 2.1 Failure Rate Bathtub Curve (© PULS LP)

2.3 Example of Components with short lifetime but long MTBF

3 Factors affecting product lifetime

3.1 Unit Life Expectancy

3.2 Electrical Stress

3.3 Mechanical Stress

3.4 Climatic Stress

3.4.2 Altitude, Air pressure

4 Lifetime prediction of key components

4.1 Aluminium Electrolytic Capacitors

4.2 Film Capacitors

4.3 Analog Optocouplers

4.6 Rechargeable Batteries

4.7 Thin Film Resistors

4.8 Electromechanical Parts (Contact Components)

4.9 Inductive Parts

4.10 Metal Oxide Varistor (MOV)

5 Conclusions: Optimized Datasheet Specification for Lifetime

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